Tray lowering assemblies and methods of manufacturing the same

ABSTRACT

A tray lowering assembly includes a securing bracket. The securing bracket includes a supporting arm which is adapted to receive and to support a tray. Specifically, when a contact pressure is applied to a predetermined portion of the supporting arm, the supporting arm pivots towards the wall. For example, the securing bracket can be pivotally connected to the wall via a wall passage formed through the wall which is adapted to receive the pivot arm, a bracket passage formed through the pivot arm, and a securing plate mounted to the wall. Moreover, the bracket passage is adapted to receive a portion of the securing plate when the first supporting arm pivots towards the wall.

[0001] The present application claims priority from U.S. Provisional Patent Application No. 60/401,352, which is entitled “Tray Lowering Assemblies and Methods of Manufacturing the Same,” and was filed on Aug. 7, 2002, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The invention relates generally to the field of tray lowering assemblies and methods of manufacturing such assemblies. More specifically, the invention is directed towards tray lowering assemblies in which securing brackets, which are adapted to hold trays of pretreated items, are pivotally connected to a wall, and are sequentially raised, e.g., sequentially raised within a holding cabinet, and methods of manufacturing such assemblies.

[0004] 2. Description of Related Art

[0005] Apparatus for raising and lowering food products during a cooking cycle are known in the art. For example, an open vat, large capacity fryer having a counterbalanced, vertically moveable lid for lowering a tray carrier holding trays containing food products is described in U.S. Pat. No. 4,930,408 to King et al. (the “'408 patent”), the disclosure of which is incorporated herein by reference. Referring to FIG. 2 of the 408 patent, a tray carrier may mount a series of five rectangular trays of a size to fit a conventional holding cabinet. Tray carriers may come in various sizes and configurations, but generally the tray carrier has a series of rigid or substantially rigid brackets or rods, which may support a tray. For example, a tray carrier for mounting a series of five rectangular trays is depicted in U.S. Pat. No. Des. 409,440 to King (the “'440 patent”), the disclosure of which is incorporated herein by reference. In this tray carrier, each tray may be supported between a pair of vertical walls on a pair of horizontal brackets. These brackets may be in the form of shelves or C-shaped supports. If tray carriers, which are configured as those depicted in the '440 patent, are used in a large capacity pressure cooker, such as that described in the '408 patent; the tray carrier may be lowered into the cooker vat when the trays are fully inserted into the carrier.

[0006] Specifically, with the arrangement described in the '408 patent, the trays initially are loaded with food product to be cooked, the trays then may be lowered into and immersed in a cooking medium. After the food product has been cooked, the trays may be removed from the tray carrier as the tray carrier is raised from the cooking medium. The trays of cooked food product may then transferred to a location for sale or distribution, or the trays may placed directly into a holding cabinet or onto storage racks without having to remove the product from the trays.

[0007] Moreover, restaurants, such as “fast food” restaurants, may precook some of the food products, e.g., chicken, beef, turkey, fish, pizza, and the like, which they later may serve to customers. Because the precooked food products may not be immediately served after cooking, the precooked food products initially may be stored in a holding cabinet. Some known holding cabinets may form an enclosure, and may include a heater, a blower for circulating heated air, and a plurality of shelves. After the food products are cooked, the precooked food products may be placed on trays, which may be placed on the shelves within the holding cabinet.

SUMMARY OF THE INVENTION

[0008] Therefore, a need has arisen for tray lowering assemblies, e.g., tray lowering assemblies used in holding cabinets, fryers, or the like, and methods of employing such tray lowering assemblies that overcome these and other shortcomings of the related art. A technical advantage of the present invention is that items may be stored in a storage area or a treatment area, which include a tray lowering assembly, with a reduced risk of damage to the tray lowering assembly or to a motor used to lower the assembly. For example, during a lowering of the assembly into the storage area or the treatment area, a tray may catch on a portion, e.g., an upper portion, such as a counter top, of the storage area or the treatment area. In the related art, when the tray catches the portion of the storage area or the treatment area, the tray may rise and apply a contact pressure to a securing bracket positioned above the tray. Because the securing bracket is fixed, the tray may become wedged between the securing bracket and the portion of the storage area or the treatment area, which may prevent the assembly from being lowered into the storage area or the treatment area. Moreover, the motor used to lower the assembly continues to operate when the tray is wedged, such that the motor, the lowering assembly, the tray, or a combination thereof, may become damaged or destroyed. In addition, food product positioned on the tray may fall from the tray, and then may have to be discarded. In contrast, in the present invention, when a tray applies a contact pressure to a securing bracket positioned above the tray, the motor, the lowering assembly, and the tray may not be damaged because the securing bracket pivots inward, thereby allowing the tray to rise above the securing bracket. Moreover, food product positioned on the tray may not fall off the tray.

[0009] According to an embodiment of the present invention, a tray lowering assembly comprises at least one securing bracket, e.g., a pair of securing brackets positioned opposite each other, and means for pivotally connecting the at least one securing bracket to a wall. A tray may include a pan, a basket, a wire mesh platform, a bucket, or similar container manufactured from metal, plastic, ceramic, or similar rigid material. For example, the at least one securing bracket may comprise a supporting arm which is adapted to receive and to support a tray, and also may comprise at least one pivot arm. Moreover, the means for securing the at least one bracket to the wall may comprise at least one wall passage formed through the wall which is adapted to receive the at least one pivot arm, at least one bracket passage formed through the at least one pivot arm, and at least one securing plate mounted to the wall. Moreover, the at least one bracket passage may be adapted to receive a portion of the at least one securing plate when the first supporting arm pivots towards the wall.

[0010] According to another embodiment of the present invention, a method of manufacturing a tray lowering assembly comprises the step of pivotally connecting a first securing bracket to a wall. Specifically, the first securing bracket comprises a first supporting arm, and when a contact pressure is applied to a predetermined portion of the first supporting arm, the first supporting arm pivots towards the wall.

[0011] Other objects, features, and advantages will be apparent to persons of ordinary skill in the art in view of the following detailed description of the invention and the accompanying drawings, which are provided by example only, and are not intended to limit the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of the present invention, needs satisfied thereby, and objects, features, and advantages thereof, reference now is made to the following descriptions taken in connection with the accompanying drawings.

[0013]FIG. 1 is front perspective view of a tray lowering assembly depicting a pair of securing brackets in a first position according to an embodiment of the present invention.

[0014]FIG. 2 is rear perspective view of the tray lowering assembly of FIG. 1 according to an embodiment of the present invention.

[0015]FIG. 3 is front perspective view of the tray lowering assembly depicting the pair of securing brackets in a second position according to an embodiment of the present invention.

[0016]FIG. 4 is rear perspective view of the tray lowering assembly of FIG. 3 according to an embodiment of the present invention.

[0017]FIG. 5 is a perspective view of a securing bracket according to an embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0018] Preferred embodiments of the present invention and their advantages may be understood by referring to FIGS. 1-5, like numerals being used for like corresponding parts in the various drawings.

[0019] Referring to FIGS. 1-5, a tray lowering assembly 100 according to an embodiment of the present invention is depicted. Tray lowering assembly 100 may comprise a first securing bracket 10, and a second securing bracket 30 positioned below first securing bracket 10. For example, first securing bracket 10 may comprise at least one pivot arm 10 a, e.g., a pair of pivot arms 10 a, and a supporting arm 10 b. Similarly, second securing bracket 30 may comprise at least one pivot arm 30 a, e.g., a pair of pivot arms 30 a, and a supporting arm 30 b. In an embodiment, supporting arm 10 b or supporting arm 30 b, or both, may be adapted to receive and to support a tray (not shown). A tray may include a pan, a basket, a wire mesh platform, a bucket, or similar container manufactured from metal, plastic, ceramic, or similar rigid material.

[0020] Tray lowering assembly 100 also may comprise means for pivotally connecting first securing bracket 10 to a first wall 50, and means for pivotally connecting second securing bracket 30 to first wall 50. Specifically, referring to FIG. 1, when first securing bracket 10 is pivotally connected to first wall 50 and receives the tray, supporting arm 10 b may be substantially perpendicular to first wall 50, such that a first initial angle θ formed between supporting arm 10 b and first wall 50 is about 90°. Nevertheless, referring to FIG. 3, because first securing bracket 10 is pivotally connected to first wall 50, when a contact pressure is applied to an underneath side of supporting arm 10 b, e.g., the side of supporting arm 10 b facing supporting arm 30 b, supporting arm 10 b moves towards first wall 50. As such, when the contact pressure is applied to the underneath side of supporting arm 10 b, first initial angle θ may be reduced, e.g., may become about 0°. For example, during a use of tray lowering assembly 100, a tray may not be properly inserted on support arm 30 b, e.g., the tray may extend more than a predetermined distance from support arm 30 b. When tray lowering assembly 100 is lowered within a storage area (not shown) or a treatment area (not shown), the tray which is supported by support arm 30 b may catch a portion of the storage area or the treatment area, such that tray rises and applies the contact pressure to the underneath side of support arm 10 b. In another example, there may be an obstruction sticking out of the storage area or a cavity of tray lowering assembly 100.

[0021] Similarly, when second securing bracket 30 is pivotally connected to first wall 50 and receives the tray, supporting arm 30 b may be substantially perpendicular to first wall 50, such that a second initial angle θ′ formed between supporting arm 30 b and first wall 50 is about 90°. Nevertheless, because second securing bracket 30 is pivotally connected to first wall 50, when a contact pressure is applied to an underneath side of supporting arm 30 b, supporting arm 30 b moves towards first wall 50. As such, when the contact pressure is applied to the underneath side of supporting arm 30 b, second initial angle θ′ may be reduced. Moreover, it will be understood by those of ordinary skill in the art that tray lowering assembly 100 may comprise first wall 50, or first wall 50 may be an element of another assembly employing tray lowering assembly 100. For example, a storage area (not shown), e.g., a holding cabinet (not shown), a fryer (not shown), such as a pressure fryer (not shown), or the like, may employ tray lowering assembly 100, and the storage area may comprise first wall 50. Further, first wall 50 may be slidably mounted to a first side wall (not shown) of the holding cabinet, such that first wall 50 may be raised or lowered within the storage area.

[0022] In an exemplary embodiment of the present invention, the means for pivotally connecting first securing bracket 10 to first wall 50 may comprise at least one first wall passage 20, e.g., a pair of first wall passages 20, formed through first wall 50. Specifically, first wall passage 20 may be adapted to receive pivot arm 10 a of first securing bracket 10. The means for pivotally connecting first securing bracket 10 to first wall 50 also may comprise at least one first bracket passage 90 formed through each pivot arm 10 a of first securing bracket 10. The means for pivotally connecting first securing bracket 10 to first wall 50 further may comprise at least one first securing plate 60 mounted to wall 50, e.g., via at least one fastener 70, such as a screw, bolt, rivet, or the like. Specifically, referring to FIG. 4, each first bracket passage 90 receives a portion of first securing plate 60 when supporting arm 10 b of first securing bracket 10 moves towards first wall 50. Similarly, the means for pivotally connecting second securing bracket 30 to first wall 50 may comprise at least one second wall passage 40, e.g., a pair of second wall passages 40, formed through first wall 50. Specifically, second wall passage 40 may be adapted to receive pivot arm 30 a of second securing bracket 30. The means for pivotally connecting second securing bracket 30 to first wall 50 also may comprise at least one second bracket passage 95 formed through each pivot arm 30 a of second securing bracket 30. The means for pivotally connecting second securing bracket 30 to first wall 50 further may comprise at least one second securing plate 80 mounted to wall 50, e.g., via at least one fastener 70, such as a screw, bolt, rivet, or the like. Specifically, referring to FIG. 4, each second bracket passage 95 receives a portion of second securing plate 80 when supporting arm 30 b of second securing bracket 30 moves towards first wall 50.

[0023] In any of the above-described embodiments of the present invention, tray lowering assembly further may comprise means for raising and lowering, e.g., mechanical devices; electrical devices; electromagnetic devices; or any combinations thereof, first wall 50. Examples of some means for raising are described in U.S. Pat. No. 6,336,395 B1, U.S. Pat. No. 6,322,831 B1, U.S. Pat. No. 6,112,646, U.S. Pat. No. 6,105,488, U.S. Pat. No. 6,009,795, U.S. Pat. No. 5,974,955, and U.S. Pat. No. 5,402,712, the disclosures of which are incorporated herein by reference in their entirety. In another example, the means for raising may comprise at least one first pulley (not shown), e.g., a first pair of upper pulleys (not shown), positioned within an opening formed in first wall 50. The means for raising also may comprise at least one second pulley (not shown), e.g., a second pair of lower pulleys (not shown), positioned below first wall 50. For example, at least a portion of the second pulleys can be vertically aligned with first wall 50. The means for raising further may comprise at least one cable (not shown) engaging a portion of the first pulley and a portion of the second pulley. For example, a first portion of the cable may be positioned on a first side of first wall 50 and a second portion of the cable may be positioned on a second side of first wall 50. The means for raising also may comprise at least one motor (not shown) operationally coupled to the second pulley, such that the motor turns or rotates the second pulley. When the motor turns the second pulley, first wall 50 may be raised or lowered depending on the direction which the motor turns the second pulley, thereby raising or lowering first securing bracket 10 or second securing bracket 30, or both.

[0024] In another example, the means for raising may comprise at least one jacking system (not shown). The jacking system may comprise at least one screw (not shown), and an engaging nut (not shown) adapted to receive screw. The jacking system also may comprise a pair of vertically extendable jack members (not shown), e.g., a pair of double scissor jack members (not shown), and a platform (not shown) connected to or mounted to the jack members (not shown). The jacking system further may comprise the motor operationally coupled to the screw, such that the motor turns or rotates the screw. Moreover, when the motor turns the screw, the jack members may extend vertically, and first wall 50 may be raised or lowered depending on the direction which the motor turns the screw. For example, when the screw moves about six inches in a horizontal direction, the jack members may move about sixteen inches in a vertical direction.

[0025] In operation, when first securing bracket 10 or second securing bracket 30, or both are lowered, e.g., via a lowering of first wall 50, and the tray supported by first securing bracket 10 or second securing bracket 30, or both, is not completely inserted onto securing bracket 10 or securing bracket 30, or both, and extends a predetermined distance from first securing bracket 10 or second securing bracket 30, or both, the tray may contact a counter top (not shown) of the holding cabinet. Similarly, when an obstruction is positioned within a cavity of tray lowering assembly 10 or within the holding cabinet, or both, the tray may contact the obstruction. That particular tray contacting the counter top or the obstruction subsequently may rise and contact the supporting arm of the securing bracket positioned above the tray, thereby causing the contacted securing bracket to pivot in a direction towards first wall 50. For example, when the tray supported by second securing bracket 30 contacts the counter top of the holding cabinet or the obstruction, the tray subsequently may rise and contact supporting arm 10 b of first securing bracket 10. This pattern may be repeated until an operation of the holding cabinet is discontinued. Nevertheless, because first securing bracket 10 and second securing bracket 30 pivot, thereby preventing the tray from becoming wedged between first securing bracket 10 and the counter top or the obstruction, a motor employed to raise and lower first wall 50 may not be damaged or destroyed when the tray applies the contact pressure to the underneath side of first securing bracket 10. Moreover, although this example is described with respect to a holding cabinet, it will be understood by those of ordinary skill in the art that similar results are obtained when assembly 100 is lowered inside a fryer (not shown), and a tray contacts a portion of the fryer or the obstruction.

[0026] In an exemplary embodiment, first wall 50 may be raised, such that first securing bracket 10 and second securing bracket 30 may be positioned above or substantially flush with the counter top of the holding cabinet. Pretreated items, e.g., precooked food products, may be placed on a first tray (not shown), e.g., a first food product tray, and pretreated items, e.g., precooked food products, may be placed on a second tray (not shown), e.g., a second food product tray. When a desired amount of pretreated items been placed on a desired number of trays, e.g., between two and about five trays depending on a number of securing brackets used by tray lowering assembly 100, first wall 50 may be lowered inside the holding cabinet. As such, each of the tray may be lowered from one position to another position, such that the first tray may be substantially flush with a horizontal plane of the opening of the counter top of the holding cabinet. Moreover, the second may be inside the holding cabinet. When all or substantially all of the items on first tray have been removed, first wall 50 may be raised from a first level to a second level. As such, each of the trays may rise from a one position to another position. Consequently, the first tray may be positioned outside the holding cabinet and the second tray may be positioned substantially flush with the horizontal plane of the opening of the counter top. Moreover, this pattern may be repeated until the tray closest to a bottom of the holding cabinet is substantially flush with the horizontal plane of the opening of the counter top. When all of the pretreated items have been removed, additional items may be positioned on the trays and tray lowering assembly 100 may be lowered inside the holding cabinet.

[0027] In another exemplary embodiment, first wall 50 may be raised, such that first securing bracket 10 and second securing bracket 30 may be positioned above or substantially flush with a top of a fryer (not shown). Uncooked food products may be placed on a first tray (not shown), and uncooked food products may be placed on a second tray (not shown). When a desired amount of uncooked food products been placed on a desired number of trays, e.g., between two and about five trays depending on a number of securing brackets used by tray lowering assembly 100, first wall 50 may be lowered inside the fryer. As such, each of the trays may be lowered from one position to another position. When all or substantially all of the food products have been cooked, first wall 50 may be raised from a first level to a second level. As such, each of the trays may rise from a one position to another position.

[0028] In still another exemplary embodiment of the present invention, a second wall (not shown) may be positioned substantially opposite first wall 50. The elements described above with respect to embodiments of the present invention which include first wall 50 also may be included with respect to embodiments including the second wall. Moreover, the features and advantages of the embodiments of the present invention which include first wall 50 are substantially the same as the features and advantages of embodiments of the present invention which include both first wall 50 and the second wall. Therefore, embodiments of the present invention which include both first wall 50 and the second wall are not further discussed.

[0029] While the invention has been described in connection with preferred embodiments, it will be understood by those of ordinary skill in the art that other variations and modifications of the preferred embodiments described above may be made without departing from the scope of the invention. Other embodiments will be apparent to those of ordinary skill in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and the described examples are considered as exemplary only, with the true scope and spirit of the invention indicated by the following claims 

What is claimed is:
 1. A tray lowering assembly, comprising: a first securing bracket comprising a first supporting arm, wherein the first supporting arm is adapted to receive and to support a first tray; and means for pivotally connecting the first securing bracket to a wall, wherein when a contact pressure is applied to a predetermined portion of the first supporting arm, the first supporting arm pivots towards the wall.
 2. The assembly of claim 1, wherein the first securing bracket further comprises at least one first pivot arm, and the means for pivotally connecting the first securing bracket to the wall comprises: at least one first wall passage formed through the wall, wherein the at least one first wall passage is adapted to receive the at least one first pivot arm; at least one first bracket passage formed through the at least one first pivot arm; and at least one first securing plate mounted to the wall, wherein the at least one first bracket passage is adapted to receive a portion of the at least one first securing plate when the first supporting arm pivots towards the wall.
 3. The assembly of claim 1, further comprising: a second securing bracket positioned below the first securing bracket and comprising a second supporting arm, wherein the second supporting arm is adapted to receive and to support a second tray; and means for pivotally connecting the second securing bracket to the wall, wherein when a contact pressure is applied to a predetermined portion of the second supporting arm, the second supporting arm pivots towards the wall.
 4. The assembly of claim 3, wherein the first securing bracket further comprises at least one first pivot arm, the second securing bracket further comprises at least one second pivot arm, and the means for pivotally connecting the first securing bracket to the wall comprises: at least one first wall passage formed through the wall, wherein the at least one first wall passage is adapted to receive the at least one first pivot arm; at least one first bracket passage formed through the at least one first pivot arm; and at least one first securing plate mounted to the wall, wherein the at least one first bracket passage is adapted to receive a portion of the at least one first securing plate when the first supporting arm pivots towards the wall, wherein the means for pivotally connecting the second securing bracket to the wall comprises: at least one second wall passage formed through the wall, wherein the at least one second wall passage is adapted to receive the at least one second pivot arm; at least one second bracket passage formed through the at least one second pivot arm; and at least one second securing plate mounted to the wall, wherein the at least one second bracket passage is adapted to receive a portion of the at least one second securing plate when the second supporting arm pivots towards the wall.
 5. The assembly of claim 3, wherein the first securing bracket is adapted to be lowered from a first position to a second position, and the second securing bracket is adapted to be lowered from the second position to a third position.
 6. The assembly of claim 5, wherein the wall is slidably mounted to a side wall of a holding cabinet.
 7. The assembly of claim 1, further comprising means for raising and lowering the wall, wherein the first securing bracket is lowered from the first position to the second position when the wall is lowered from a first level to a second level.
 8. The assembly of claim 1, wherein the first tray is a food product tray.
 9. A tray lowering assembly, comprising: a first pair of securing brackets, wherein a first of the first pair of securing brackets comprises a first supporting arm adapted to receive and to support a first tray, and wherein a second of the first pair of securing brackets comprises a second supporting arm adapted to receive and to support the first tray; means for pivotally connecting a first of the first pair of securing brackets to a first wall, wherein when a contact pressure is applied to a predetermined portion of the first supporting arm, the first supporting arm pivots towards the first wall; and means for pivotally connecting a second of the first pair of securing brackets to a second wall, wherein the second wall is positioned opposite the first wall, and when a contact pressure is applied to a predetermined portion of the second supporting arm, the second supporting arm pivots towards the second wall.
 10. The assembly of claim 9, wherein the first of the first pair of securing brackets further comprises at least one first pivot arm, and the means for pivotally connecting the first of the first pair of securing brackets to the first wall comprises: at least one first wall passage formed through the first wall, wherein the at least one first wall passage is adapted to receive the at least one first pivot arm; at least one first bracket passage formed through the at least one first pivot arm; and at least one first securing plate mounted to the first wall, wherein the at least one first bracket passage is adapted to receive a portion of the at least one first securing plate when the first supporting arm pivots towards the first wall.
 11. The assembly of claim 10, wherein the second of the first pair of securing brackets further comprises at least one second pivot arm, and the means for pivotally connecting the second of the first pair of securing brackets to the second wall comprises: at least one second wall passage formed through the second wall, wherein the at least one second wall passage is adapted to receive the at least one second pivot arm; at least one second bracket passage formed through the at least one second pivot arm; and at least one second securing plate mounted to the second wall, wherein the at least one second bracket passage is adapted to receive a portion of the at least one second securing plate when the second supporting arm pivots towards the second wall.
 12. The assembly of claim 9, further comprising: a second pair of securing brackets, wherein a first of the second pair of securing brackets comprises a third supporting arm adapted to receive and to support a second tray, and wherein a second of the second pair of securing brackets comprises a fourth supporting arm adapted to receive and to support the second tray; means for pivotally connecting a first of the second pair of securing brackets to the first wall, wherein the first of the second pair of securing brackets is positioned below the first of the first pair of securing brackets, and when a contact pressure is applied to a predetermined portion of the third supporting arm, the third supporting arm pivots towards the first wall; and means for pivotally connecting a second of the second pair of securing brackets to the second wall, wherein the second of the second pair of securing brackets is positioned below the second of the first pair of securing brackets, and when a contact pressure is applied to a predetermined portion of the fourth supporting arm, the fourth supporting arm pivots towards the second wall.
 13. The assembly of claim 12, wherein the first pair of securing brackets are adapted to be lowered from a first position to a second position, and the second pair of securing brackets are adapted to be lowered from the second position to a third position.
 14. The assembly of claim 12, wherein the first wall is slidably mounted to a first side wall of a holding cabinet, and the second wall is slidably mounted to a second side wall of the holding cabinet.
 15. The assembly of claim 9, wherein the first tray is a food product tray.
 16. The assembly of claim 9, further comprising: means for raising and lowering the first wall, wherein the first securing bracket is lowered from the first position to the second position when the wall is lowered from a first level to a second level; and means for raising and lowering the second wall, wherein the second securing bracket is lowered from the first position to the second position when the second wall is lowered from the first level to the second level.
 17. A method of manufacturing a food tray assembly, comprising the step of: pivotally connecting a first securing bracket to a wall, wherein the first securing bracket comprises a first supporting arm, and when a contact pressure is applied to a predetermined portion of the first supporting arm, the first supporting arm pivots towards the wall.
 18. The method of claim 16, further comprising the step of: pivotally connecting a second securing bracket to the wall, wherein the second securing bracket comprises a second supporting arm, and when a contact pressure is applied to a predetermined portion of the second supporting arm, the second supporting arm pivots towards the wall. 